Modular Ultracapacitor Packaging with Thermal Management
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Solution Overview
Problem
Batteries in various applications, such as hybrid vehicles, suffer from short life expectancy and low power density due to chemical reactions, which limits their performance and payback time, whereas ultracapacitors offer improved power density and life expectancy but require appropriate packaging and connection systems for efficient use.
Innovation Solution
A modular ultracapacitor energy storage system with a coupling system for series or parallel connections, incorporating a controller for voltage monitoring and fault detection, along with a mechanical design for easy installation and safe handling, featuring heat sinks for thermal management and busbars for efficient heat dissipation, housed in a water-sealed, reinforced, and vibration-resistant enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batteries are used for energy storage, then energy storage capacity is achieved, but life expectancy and power density are reduced
Solution Approach 1:
The system segments the energy storage function into two distinct components: batteries for energy storage capacity and ultracapacitors for power density and peak power handling. This segmentation allows each component to operate in its optimal performance range, resolving the contradiction by assigning different functional roles to different storage technologies rather than relying on a single technology to fulfill all requirements.
2Quantity of substance
If batteries are used for energy storage, then energy storage capacity is achieved, but power density is reduced
Solution Approach 1:
The system merges batteries and ultracapacitors into a hybrid energy storage system where both technologies work together. The ultracapacitor module with high power density handles peak power demands and transient loads, while the battery provides sustained energy storage capacity. This merging allows the system to achieve both high energy storage capacity and high power density simultaneously.
3Power
If ultracapacitors are used for high power density, then power density and life expectancy are improved, but appropriate packaging and connection systems are required
Solution Approach 1:
The connection module serves multiple functions simultaneously: it provides electrical connections for series/parallel configuration of ultracapacitors, mechanical support and alignment through the frame structure, thermal management pathways, and modular assembly/disassembly capabilities. This multi-functionality reduces the need for separate specialized components, simplifying the overall packaging and connection system while enabling the high power density benefits of ultracapacitors.
4Power
If ultracapacitors are used in series connection, then voltage is increased, but thermal management requirements increase
Solution Approach 1:
The connection module acts as an intermediary between series-connected ultracapacitors, providing dedicated thermal pathways through heat sinks and conductive thermal interfaces. This intermediary structure enables efficient heat dissipation from each capacitor in the series string, managing thermal accumulation that would otherwise result from high-voltage operation while maintaining the voltage benefits of series connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a high-power, long-lasting energy storage solution with enhanced safety and reliability, suitable for automotive and stationary applications, reducing fuel consumption and extending the lifespan of energy storage systems while ensuring secure and efficient operation.
Implementation Method 1
heat sinks for thermal management
Implementation Method 2
heat sinks for thermal management
Implementation Method 3
busbars for efficient heat dissipation
Data Source
AI summary
An ultracapacitor energy storage system and in particular a system for packaging and connecting ultracapacitors for energy storage purposes is described which is applicable in automotive and stationary applications. The ultracapacitors in the system can be in series or parallel or a combination of both. A controller, relays, voltage monitoring and isolation fault detection are used to regulate the system. The mechanical construction of frame and different pluggable modules lead to an easy in- and deinstallation of the different parts. The different constructions are designed with a safe handling by the operator in mind.